Lightweight, Collapsible Axial Wind Generator

ABSTRACT

A wind generator that includes a lightweight, collapsible blade assembly mounted on a supporting structure that holds the blade assembly in fixed position that is exposed to low to moderate winds. The blade assembly is coupled to the distal end of a drive shaft linked to a low RPM, axial magnetic generator designed to produce A.C. electric current when rotated at low speeds. The blade assembly is a cylindrical structure with a longitudinally axis. Coaxially aligned around the longitudinal axis is an outer blade component and an inner blade component. The outer blade component is a non-rotating structure which includes a plurality of directional blades designed to direct the wind into and towards the blades on the inner blade assembly. The inner blade component is designed to rotate inside the outer blade component and coupled to the generator&#39;s drive shaft. The blades on the inner and outer blade assemblies are made of flexible, lightweight material that enable them to be fully extend when exposed to low and moderate winds or collapse in the blade assembly when exposed to high winds or during repairs. Control mechanisms are provided for automatically extending and retracting the blades on the inner and outer blade components.

This utility patent application is based and claims the filing date benefit of U.S. Provisional patent application (Application No. 61/349,652) filed on May 28, 2010.

Notice is hereby given that the following patent document contains original material which is subject to copyright protection. The copyright owner has no objection to the facsimile or digital download reproduction of all or part of the patent document, but otherwise reserves all copyrights whatsoever.

BACKGROUND OF THE INVENTION

1. Field of the Invention

This invention pertains to wind generators, and more specifically to scalable wind generators to be used in low to high velocity winds.

2. Description of the Related Art

Wind power is widely accepted as an environmental friendly means for producing energy. Unfortunately, wind generators being used or under development today use large and expensive turbine generators mounted at a fixed position on the end of a large pole or tower. The generators include large radially aligned blades that interface with the wind and cause the generator to axially rotate. Because the blades are large and rotate in a vertical circular pattern at the end of the generator, the generator must be mounted on large pole and tower.

Typically, a plurality of wind generators are constructed in designated areas regularly exposed to moderate winds. These dedicated areas are often referred to as wind farms, where a plurality of generators are equally spaced apart and aligned in rows. Because the cost of each wind generator and the land is relatively large, they are typically set-up and operated by large private companies or public municipalities.

One drawback with these large wind generators found in the prior art is that they block views, distract and destroy the natural beauty of the region, and are environmental hazards for indigenous insects and animals.

Another drawback with these large wind generators is that they are not well suited for regions where the wind blows in different directions or varies in velocity.

Another drawback with these large wind generators is that they are not ‘cost effective’ for individual homeowners or neighborhoods.

What is needed is a cost effective, scalable wind generator that can be used in low to high wind environments, that is relatively small and lightweight, can be safely mounted and operated on a roof top, wall or deck or a small area of the yard, and is self-monitoring for high wind conditions so that it automatically adjust to a protective configuration during high wind conditions.

SUMMARY OF THE INVENTION

The above listed drawbacks are addressed and satisfied by the wind generator disclosed herein that includes a lightweight, collapsible blade assembly mounted on a supporting structure that holds the blade assembly in a fixed position and exposed to low to moderate winds. The blade assembly is a cylindrical structure that includes an outer fixed blade component coaxially aligned around an inner rotating blade component. The fixed outer blade component is a fixed structure designed to direct wind into the rotating inner blade component that is designed to freely rotate in response to the wind. The inner blade component is coupled to the drive tube connected to a low RPM, axial magnetic generator designed to produce A.C. current when rotated at low speeds.

The fixed outer blade component includes a top circular plate and a lower circular plate. Extending between the two plates is a plurality of lightweight blades. The blades are radially and longitudinally aligned between the two circular plates. Extending longitudinally on the outside edges and the middle of each blade are two or more parallel rods. The two rods extend parallel and through seams located along the opposite outer edges of the blades.

In one embodiment, the blades on the outer blade component are designed to selectively extend to direct wind into the rotating inner blade component and selectively retract or collapse during high wind conditions to prevent their destruction. Located on the outer edges of the blades are inner and outer rods that are affixed to the upper and lower circular plates and used to hold the fixed blade in a longitudinally position between the two circular plates. One end of the each blade is able to slide freely over the inner and the outer rods to extend or retract the blade. A means for controlling the extending and retracting movement of all or a sections of blade is also provided. In one embodiment the means for controlling the extension and retraction of the blades is a circular ring attached to the upper edges of the blades that is raised or lowered inside the two circular plates. During operation, the circular ring selectively moves up and down in the space between the two circular plates which causes the blades on the outer blade component to selectively extend and collapse between the two circular plates. The rotating inner blade component includes a plurality of vertically aligned blades evenly spaced apart and parallel to the blades on the outer blade components. The inner blade components includes an upper and lower sail plates. Extending laterally from each upper and lower sail plate are fixed curved ribs. Extending between the curved ribs on the upper and lower sail plates are three rods. Located between the two sail plates in a middle sail plate with curved ribs. The upper edges each blade is attached to the curved ribs on the middle sail section. The middle sail section is able to slide freely up and down over the three rods

In one embodiment, the blades on the inner blade component, like the blades on the outer blade component, are also designed to selective extend and retract during light winds and high winds, respectively. In one embodiment, extending between the three sail plates is a rotating drive tube. Located inside and around the drive tube is a thread acme rod that connects to an inner magnetic coupler that move longitudinally inside the drive tube when the acme rod is rotated. The drive tube extends through the outer magnetic coupler attached to the middle sail plate. The inner and outer magnetic couples include magnets that are magnetically attracted to each other. By rotating the acme rod inside the drive tube, the inside magnetic coupler moves longitudinally inside the drive tube and moving the middle sail plate. Because the top edge of each blade is attached to the middle sail plate, when the inside magnetic coupler moves upward and downward inside the drive tube, the blades extend or retract, respectively, inside the upper and lower sail plates. A motor is connected to the acme rod to connected control movement of the middle sail plate.

During operation, the inner blade component is designed to rotate inside the outer blade component. The blades on the inner and outer blade components are made of flexible, lightweight material and fully extend when exposed to low and moderate winds. Depending on wind conditions, wind and electrical output sensors may be used to control the movement of the two fixed and rotating blades on the two blade components.

A programmable logic controller coupled to voltage, amperage, wind velocity and wind direction sensors to control extension and extraction of the blades on the inner and outer blade components. Also, signage or advertising indicia may be imprinted to attached to the outside surface of the blades on the outer blade components. The programmable logic controller may be used to retract the blades on the inner blade component but keep the blades on the outer blade components extended during high winds since these blades do not rotated.

DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view of the lightweight, collapsible axial wind generator shown mounted on three support legs with the blades on the inner and outer blade components shown in an extended position.

FIG. 2 is a side elevational view of the wind generator shown in FIG. 1 showing the direction of the wind against the outer blade component.

FIG. 3 is a top plan view of the wind generator shown in FIGS. 1 and 2.

FIG. 4 is a perspective of the adjustable wind generator similar to the view shown in FIG. 1 with the blades on the inner and outer blade components shown in a collapsed position.

FIG. 5 is a side elevational view of the wind generator similar to the view shown in FIG. 2 with the blades on the inner and outer blade components in a collapsed position.

FIG. 6 is a bottom plan view of the wind generator shown in FIGS. 1-5.

FIG. 7 is a partially exploded, top perspective view of the outer blade component.

FIG. 8 is a bottom plan view of the lower housing plate on the outer blade component showing the relative locations of the directional blade drive motor, the pulleys, and the drive cords.

FIG. 9 is a perspective view of the generator with the fixed outer blade component with the rotating inner blade component removed and showing the relative locations of the three guide tubes, the cords, and the upper circular ring used to lower and raise the directional blades.

FIG. 10 is a bottom plan view of the wind generator.

FIG. 11 is a partial side perspective view showing an upper pulley located on the upper housing plate and how the cords extend upward through a guide tube and then around the pulley and connect to the upper circular ring.

FIG. 12 is an exploded, perspective view on the inner blade component showing the two end sail plates and the middle sail plate in a partially elevated position on the drive tube.

FIG. 13 is a top plan view of the upper end sail plate with the blades attached thereto.

FIG. 14 is a top perspective view of an assembled inner blade component showing the middle sail plate in an extended position adjacent to the upper end plate so that the inner blades are fully extended.

FIG. 15 is a top plan view of the middle sail plate showing the drive tube opening with the drive tube located therein.

FIG. 16 is a perspective of the drive tube with the outside magnetic coupler located in the retracted position.

FIG. 17 is a perspective view of the outside coupler mounted on the acme rod.

FIG. 18 is a perspective view of the coupler block mounted on the acme rod and connected to motor assembly.

FIG. 19 is a partial top plan view of the middle plate showing the relative positions of the inside and outside couplers and the drive tube.

FIG. 20 is a partial, sectional side elevational view of the drive tube shown in FIG. 19.

FIG. 21 is a partial lower perspective view of the lower sail plate shown being attached to the drive shaft extension on one side and to the drive tube on the opposite side.

FIG. 22 is an exploded, perspective view of the generator.

FIG. 23 is a bottom perspective view showing an alternative outer blade component in which three sections of blades on the outer blade component are able to independent extend and retract.

FIG. 24 is a top plan view of a building with the wind generator mounted on the eave.

FIG. 25 is a side, elevational view of the wind generator mounted on the eave as shown in FIG. 24.

FIG. 26 is a front, elevational view of the wind generator shown in FIGS. 24 and 25.

FIG. 27 is an illustration of the menu page generated the maximum power point tracking software program that is used to adjust the load on the generator assembly so that it operates efficiently.

FIG. 28 is a flow diagram showing how the generator connected to the household electrical grid.

DESCRIPTION OF THE PREFERRED EMBODIMENT(S)

Referring to the accompanying FIGS. 1-28, there is shown a wind generator 10 disclosed herein that includes a lightweight, collapsible blade assembly 12 mounted on a supporting structure 14 that holds the blade assembly 12 in fixed position and exposed to low to moderate winds 5.

The blade assembly 12 is coupled to the distal end of a vertically aligned drive shaft 32 linked to a low RPM, axial magnetic generator 30 designed to produce A.C. current when rotated at low speeds. The blade assembly 12 is a cylindrical structure with a longitudinally axis 20. Coaxially aligned around the longitudinal axis 20 is a fixed outer blade component 40 and a rotating inner blade component 70. The outer blade component 40 is a non-rotating structure which includes a plurality of directional, fixed or non-rotational blades 50 designed to direct the wind into and towards the blades 90 on the inner blade component 70 facing the wind 5.

As shown in FIGS. 7-10 shows one embodiment of the outer blade component 40 includes a top circular plate 42 and a lower circular plate 46. Extending between the two plates 42, 46 is a plurality of lightweight blades 50. The blades 50 are radially and longitudinally aligned between the two circular plates 42, 46. Extending longitudinally on the outside edges and the middle of each plate 42, 46 are three parallel rods 52, 54, 56 that extend through the outer edges of the blades 50. The opposite ends of the inner and outer rods 52, 56 are affixed to the upper and lower circular plates 42, 46, and used to hold the blades 50 in a longitudinally between the two circular plates 42, 46. The ends of the blades 50 are able to slide freely over the inner and the outer rods 52, 56. The middle rod 54 is attached to the center axis of the blade 50 and is attached at its lower end to the lower circular plate 46 while the upper end of the middle rods are attached to the upper circular ring 60 and used primarily as a support structure for the two plates 42, 46.

It should be understood that the outer blade assembly 40 and the inner blade assembly 70 could be manufactured to be extended continuously. In the preferred embodiment, the blades 50 on the inner blade assembly 40 and the blades 80 on the inner blade assembly 70 are designed to collapse during moderate to high winds.

In one embodiment, the means for selectively controlling the extending and collapsing of the upper plate 42 is a circular ring 60 that, during operation, moves up and down between the two circular plates 42, 46 to selectively extend and collapse the blades 50 between the two circular plates 42, 46. FIG. 7 is a top perspective view of the outer blade component 40 showing cords 146 that extend lower from the circular plate 46 and that extend upward through three, longitudinally aligned hollow tubes 150. The tubes 150 are radially and equally spaced apart between the upper and lower plates 42, 46. As shown in FIGS. 8 and 9, the three cords 146 extend inward and around five pulleys 148 located on the bottom surface of the lower circular plate 46. Holes are formed on the lower circular plate 46 that are aligned and registered with the tubes 150 so the cords 146 may extend upward towards the upper circular plate 42. As shown in FIG. 11, the cords 146 extend through the upper circular plate 42 and around pulleys 149 mounted thereon and then back down through the upper circular plate 42 and connect to the upper ring 60. The opposite end of each cord 146 is connected to the edge of a blade 50 and pulls the blade 50 downward into a collapsed position.

As shown in FIG. 3, the inner blade component 70 is designed to rotate inside the outer blade component 40. The blades 50 on the outer blade component 40 direct the wind 5 against the blades on the inner blade component 70 causing it to rotate and turn the generator. As shown in FIGS. 12-15, the inner blade component 70 includes two end sail plates 74, 90 and at least one intermediate or middle sail plate 86. Each sail plate 74, 86, 90, includes a plurality of fixed, curved ribs 76, 88, 92, respectively, that extend radially outward. The three sail plates 74, 86, 90 are aligned and registered so that their respective ribs 76, 88, 92 are aligned and registered. Extending between the stacked ribs on the three sail plates 74, 86, and 90 is a lightweight, collapsible rotating blade 100.

The means for selectively collapsing the inner blade assembly 70 includes three sail plates 74, 86, 90 coaxially aligned over a rotating drive tube 110. Locating inside and around the drive tube 110 are two magnetic coupler sets 120, 140 that moved longitudinally over the drive tube 110. The outside magnetic coupler set 120 includes two brackets 122 each attached around the square-shaped bore formed on the middle sail plate 86. Attached to inside the vertical surface on each bracket 122 is a flat magnet 124. The inside magnetic coupler 140 is designed to move longitudinally inside the drive tube 110. The inside magnetic coupler 140 includes a square-shaped body 142 with a center passageway 144. Formed on the upper edges of the body 142 are four wheels 146 that rotate and allow the coupler 140 to move longitudinally upward and downward on the acme rod 150 and inside the drive tube 110. Attached to the four planar side surfaces of the body 142 are four flat magnets 143.

The drive tube 110 is made of non-magnetic attractive material, such as stainless steel or plastic. The magnets on four outside surfaces of the four outer magnetic brackets and on the inner magnetic coupler are magnetically attracted to each other when placed in close proximity of each other. During assembly, the inside magnetic coupler 140 is connected to a threaded acme rod 150 that when rotated, causes the inside magnetic coupler 140 to move upward and downward inside the drive tube 110. When the acme rod 150 is rotated, the inside magnetic coupler 140 moves upward in the drive tube 110 and is aligned with the outside magnetic brackets 122. When the acme rod 150 is rotated, the outside magnetic coupler brackets 120 and the middle sail plate 84 moves up and down inside the blade assembly 12.

As shown in FIG. 18, the end of the acme rod 150 is connected to a D.C. motor 160 that is affixed to the top surface of the lower sail plate 74. The lower end of the drive tube 110 is coaxially aligned and affixed to the top surface of the lower sail plate 74. As shown in FIG. 21, attached to the bottom surface of the lower sail plate 74 is an intermediate drive shaft 200 that extends downward through a centrally aligned bushing 48 located on the lower circular plate (not shown) that connects to the main drive shaft 32 connected to the generator 30.

In the embodiment shown herein, there are seven blades 50 on the outer blade component 40 and six blades 100 on the inner blade component 80. The exact number of blades can vary depending on the wind conditions and the desired electrical output. In the preferred embodiment, each blade 50, 100 is made of durable, collapsible, lightweight material, such as Nylon, and designed to repeatedly extend or collapse under different wind conditions.

To control the extending and collapsing movement of the outer and inner blade components 40, 70, sensors 410, 440, and 450 are connected to motors 160 that monitor the wind speed, voltage and amperage outputs of the electric generator 30. As stated below, a programmable logic controller monitors the sensors and then produces the necessary signals and transmits them to the motors to automatically extend or collapse the blades 50, 100.

FIG. 23 is a bottom perspective view showing the outer blade component 40 in which three sections of blades 50 on the outer blade component 40 are able to independent extend and retract. Each blade includes two parallel rods located on one side that enables each blade to move longitudinally upward and downward Three drive mechanism connected to motors controlled by the PLC control cords that extend along the bottom of the lower circular plate and the upward and downward on each blade to control its extension and retraction. During operation, the section of blades facing the wind are extended while the section of blades facing laterally or away from the wind are retracted which enables air to escape from the inner blade component and improve efficiency.

As shown in 1, 2, 6, 10, and 22 and 10, a low RPM axle generator 30 is located below the lower plate and includes a vertical drive shaft 32 that extends upward and connects to the inner blade component. The low RPM axle generator 30 is identical to the low RPM axial generator disclosed in U.S. patent application Ser. Nos. 12/228,316, filed on Aug. 11, 2008 and 12/698,914, filed Feb. 2, 2010 which are now incorporated by reference herein. The generator 30 shown in FIG. 22, includes a rotating drive axle with a fixed circular ring housing. The drive axle is coaxially aligned with the outer casing. Mounted on the drive axle and located inside the outer casing is a flat stator disc on which a plurality of coil track loops are radially aligned. In the preferred embodiment, there are three types of coil track loops that are alternately aligned on the opposite sides of the stator disc. The three types of coil track loops are serially connected together by three wires that extend through the drive axle. The ends of the three wires extend through the end of the drive axle that extends through the outside plate of the ring housing and connect to a rectifier discussed further below. With three wires, a three phase A.C. electric current is created when the outer casing is rotated around the stator disc.

The stator disc is made of non-metallic material such as fiberglass. Each coil track loop is made of copper which is radially aligned in the stator disc. During operation, the stator disc becomes hot. To reduce heat an optional feature, a means for cooling the stator disc may also be provided. In one embodiment, the means for cooling is a loop conduit that is wound in a spiral configuration inside the stator disc. During use, a coolant continuously flows into the conduit through the track loops and then outward to a cooling radiator (not shown) to remove excess heat from the stator disc.

The generator 30 is connected to an adjustable inverter 600. The inverter 600 includes electronics (hardware) and a software program 620 that allows the operator to adjust the amount of load on the generator 30 so that a base line measurement (electrical power usage (Watts), and wind velocity) are maintained. When initially installed and exposed to outside wind, an energy audit of the old system if first conducted. During the energy audit, the amount of electrical energy used, and the average velocity of the wind are measured. These two parameters provide a baseline for the generator 30. The load on the generator 30 is then adjusted to that the baseline is obtained.

After the energy audit is conducted, a portable computer (i.e laptop) with a maximum power point tracking software program 590 (known as a MPPT software program) loaded into its memory. Such programs are commonly available through companies that manufacture electrical inverters. The portable computer is then connected to a communication port on the inverter 600. The software program 590 is then executed and the electrical power, velocity and pressure differentials are then inputted to the portable computer. The software program 620 generates the menu page shown in FIG. 26, which the operator then uses the software program 590 to adjust the amount of load exerted by the inverter 600 so that the generator 30 operates most efficiently.

In one embodiment, the extension and retraction of the blades on the outer blade component are also controlled by the programmed logic controller PLC 550. The controller 550 is connected to the voltage and amperage sensors and wind velocity sensors as discussed above and also to wind direction sensor 725. When wind direction sensors 725 detect wind from a specific direction, the blades 50 on the outer blade component 40 on the side of the assembly 12 facing the wind 5 are extended and blades 50 on the opposite side of the outer blade component 40 are retracted. By retracting the blades 50 on the side of the outer blade component 40 opposite the wind 5, air is able to flow away quickly from the inner blade component 70 to reduce drag. The four sensors 410, 440, 450, and 460, are coupled to a programmable logic controller 550 so that the output from all four sensors 410, 440, 450, and 460 are constantly monitored. The controller 5500 is controlled by a software program 510 that enables the user to program the desired sensor setting depending on the upper and lower wind velocity ranges and the size of the generator 30

The wind generator 10 is lightweight and may be mounted on a three-legged stand 14 as shown in FIGS. 1-5, or on a vertical pole stand 14′ as shown in FIG. 22-24. In both stands 14, 14′, the generator 30, which is the heaviest component, is supported on or near the ground. The blade assembly 12 is considerably lighter than the generator 30 may be easily supported by the eave or roof of a building 300. In FIGS. 21-23, the vertical pole is vertically aligned against a building with brackets used to hold the vertically pole in place. The blade assembly is then mounted on lightweight platform located near the eave or roof so that it may be exposed to wind.

FIG. 26 is an illustration of the menu page 330 generated the maximum power point tracking software program that is used to adjust the load on the generator 30 so that it operates efficiently.

FIG. 27 is a flow chart that shows how the wind generator 10 is connected is a utility grid or to the building electrical system. The generator 30 is connected to a disconnect switch 400. The disconnect switch 400 is connected to a rectifier 500 which is connected to the inverter 600. The inventor 600 is connected to a second disconnect switch 700 and then to a load center 800. The load center 800 is then connected to the utility gird or to the building's electrical system to supply A.C. current thereto.

As stated above the programmable logic controller is coupled to voltage, amperage, wind velocity and wind direction sensors to control extension and extraction of the blades on the inner and outer blade components. As shown in FIGS. 2 and 3, optional signage or advertising indicia 480 may be imprinted to attached to the outside surface of the blades 30 on the outer blade component 30. The programmable logic controller may be used to retract the blades 100 on the inner blade component 70 but keep the blades 50 on the outer blade component 30 extended during high winds since these blades do not rotated.

As shown in FIGS. 2 and 3, signage or advertising indicia may be imprinted to attached to the outside surface of the blades 50 on the outer blade component 40. The programmable logic controller may be used to retract the blades 100 on the inner blade component 70 but keep the blades 50 on the outer blade component 40 extended during high winds since these blades do not rotated.

In compliance with the statute, the invention described herein has been described in language more or less specific as to structural features. It should be understood however, that the invention is not limited to the specific features shown, since the means and construction shown, is comprised only of the preferred embodiments for putting the invention into effect. The invention is therefore claimed in any of its forms or modifications within the legitimate and valid scope of the amended claims, appropriately interpreted in accordance with the doctrine of equivalents. 

1. A wind generator, comprising: a. a lightweight, collapsible blade assembly, said blade assembly being a cylindrical structure with a longitudinally axis, said blade assembly includes an outer blade component and an inner blade component, said outer blade component is a non-rotating structure which includes a plurality of directional blades designed to direct the wind into and towards the blades on the inner blade component, said inner blade component is designed to rotate inside the blade assembly, said blades on said outer blade component and said inner blade component are made of flexible, lightweight material that enable them to be fully extended in the blade assembly when exposed to low and moderate winds or collapsed in the blade assembly when exposed to high winds or during repairs; b. a support structure connected to said blade assembly and used to hold said blade assembly in a wind exposed area; and, c. a low RPM, axial magnetic generator connected to said inner blade component.
 2. The wind generator as recited in claim 1, further including control mechanisms that automatically extending and retracting said blades on said outer and inner ring components under different wind conditions. 